US5086084A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Polyvinyl chloride/polyurethane hybrid foams
Assignee: ENDUR-ALL TECHNOLOGIES Inc
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Filing: 1990-04-18
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Granted: 1992-02-04
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Expires: 2010-04-18
Abstract
Abstract Disclosed is a foamed polymeric material comprising a continuous phase of polyurethane having solid polyvinyl chloride particles dispersed therein. The material preferably comprises about 100 parts of a foamable urethane, and 10 to 50 parts polyvinyl chloride particles having a particle size below 200 microns. The material has a microcellular structure with cells preferably on the order of 0.1 mm in average diameter or less. The walls comprise a matrix of polyurethane reinforced with PVC particles. The material may be used as a wood substitute.
Inventors
- 👤 William Michaelson
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 09:01
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/0061; C08L; C08L75/00; C08L75/04; C08G; C08G2110/00; C08G2110/0008; C08G2110/0025; C08G2110/0033; C08G2110/0041; C08G2110/0066; C08J2375/00; C08J2375/04; C08J2427/00; Y; Y10; Y10S; Y10S521/00; Y10S521/908
Claims Analysis
Total Claims: 25
Claim 1
Independent Claim
73 words
A foamed rigid polymeric material comprising a continuous phase of polyurethane defining a multiplicity of microcells no greater than about 1 millimeter in diameter, said continuous phase containing integral, substantially uniformly dispersed solid polyvinyl chloride particles having surface features effective to provide a multiplicity of seed bubble sites and serving to stabilize and reinforce said mircocellular structure of said foamed polymeric material to produce a rigid structure approximating the mechanical properties of woods.
Claim 2
Dependent Claim
73 words
A foamed rigid polymeric material comprising a continuous phase of polyurethane defining a multiplicity of microcells no greater than about 1 millimeter in diameter, said continuous phase containing integral, substantially uniformly dispersed solid polyvinyl chloride particles having surface features effective to provide a multiplicity of seed bubble sites and serving to stabilize and reinforce said mircocellular structure of said foamed polymeric material to produce a rigid structure approximating the mechanical properties of woods.
Claim 3
Dependent Claim
19 words
The material of claim 1 wherein the continuous phase defines cells uniformly no greater than 0.1 millimeter in diameter.
Claim 4
Dependent Claim
27 words
The material of claim 1 wherein the polyvinyl chloride particles have an average diameter within the range of 5 microns to 50 microns and an irregular surface.
Claim 5
Dependent Claim
32 words
The material of claim 1 further comprising a surface layer integral with said continuous layer and consisting essentially of an unexpanded continuous phase of polyurethane having solid polyvinyl chloride particles dispersed therein.
Claim 6
Dependent Claim
18 words
The material of claim 1 comprising 100 parts polyurethane and between 10 and 50 parts polyvinyl chloride particles.
Claim 7
Dependent Claim
18 words
The material of claim 5 comprising 100 parts polyurethane and between 15 and 40 parts polyvinyl chloride particles.
Claim 8
Dependent Claim
32 words
The material of claim 1 having a density of between 20 pounds per cubic foot and 50 pounds per cubic foot (320 kilograms per cubic meter and 800 kilograms per cubic meter).
Claim 9
Dependent Claim
20 words
The material of claim 1 wherein the polyurethane comprises the product of reaction of a diphenylmethane diisocyanate and a polyol.
Claim 10
Dependent Claim
12 words
The material of claim 8 wherein the polyol comprises a polyether polyol.
Claim 11
Dependent Claim
9 words
A structural element comprising the material of claim 1.
Claim 12
Dependent Claim
101 words
A composition for producing a rigid microcellular polyvinylchloride-reinforced polyurethane foam consisting essentially of: 100 parts of a foamable polyurethane prepolymer mixture including a polyol, a multifunctional isocyanate and a blowing agent in relative amounts sufficient to produce a polyurethane foam polymer; and 10 to 50 parts of polyvinylchloride particles having a particle size range below about 200 microns, and having surface features effective to provide a multiplicity of seed bubble sites, the relative amounts of the polyurethane prepolymer mixture, blowing agent and particles being sufficient to produce upon reaction a rigid microcellular foam structure which approximates the mechanical properties of wood.
Claim 13
Dependent Claim
101 words
A composition for producing a rigid microcellular polyvinylchloride-reinforced polyurethane foam consisting essentially of: 100 parts of a foamable polyurethane prepolymer mixture including a polyol, a multifunctional isocyanate and a blowing agent in relative amounts sufficient to produce a polyurethane foam polymer; and 10 to 50 parts of polyvinylchloride particles having a particle size range below about 200 microns, and having surface features effective to provide a multiplicity of seed bubble sites, the relative amounts of the polyurethane prepolymer mixture, blowing agent and particles being sufficient to produce upon reaction a rigid microcellular foam structure which approximates the mechanical properties of wood.
Claim 14
Dependent Claim
14 words
The composition of claim 11 comprising between 15 and 40 parts polyvinyl chloride particles.
Claim 15
Dependent Claim
18 words
The composition of claim 11 wherein the polyvinyl chloride particles range in size between 5 and 50 microns.
Claim 16
Independent Claim
186 words
A method of manufacturing a rigid structural element having a predetermined density, tensile strength and compressive strength approximating those of wood comprising: providing a composition comprising: 100 parts of a foamable polyurethane prepolymer mixture comprising a polyol, a multifunctional isocyanate, and a blowing agent in relative amounts sufficient to produce a polyurethane foam polymer, and 10 to 50 parts of polyvinyl chloride particles having a particle size range below about 200 microns, said particles having surface features effective to provide a multiplicity of seed bubble sites; introducing the composition into a mold defining the shape of the structural element, and reacting the polyol and the multifunctional isocyanate in the presence of the blowing agent and the polyvinyl chloride particles to fill the mold with a continuous phase of rigid polyurethane defining a multiplicity of cells produced at said seed bubble sites, smaller than about 1 millimeter in diameter, and containing said solid polyvinyl chloride particles dispersed substantially uniformly throughout the continuous phase, said continuous phase having an integral surface layer consisting essentially of an unexpanded continuous phase of polyurethane having said polyvinyl chloride particles dispersed therein.
Claim 17
Independent Claim
186 words
A method of manufacturing a rigid structural element having a predetermined density, tensile strength and compressive strength approximating those of wood comprising: providing a composition comprising: 100 parts of a foamable polyurethane prepolymer mixture comprising a polyol, a multifunctional isocyanate, and a blowing agent in relative amounts sufficient to produce a polyurethane foam polymer, and 10 to 50 parts of polyvinyl chloride particles having a particle size range below about 200 microns, said particles having surface features effective to provide a multiplicity of seed bubble sites; introducing the composition into a mold defining the shape of the structural element, and reacting the polyol and the multifunctional isocyanate in the presence of the blowing agent and the polyvinyl chloride particles to fill the mold with a continuous phase of rigid polyurethane defining a multiplicity of cells produced at said seed bubble sites, smaller than about 1 millimeter in diameter, and containing said solid polyvinyl chloride particles dispersed substantially uniformly throughout the continuous phase, said continuous phase having an integral surface layer consisting essentially of an unexpanded continuous phase of polyurethane having said polyvinyl chloride particles dispersed therein.
Claim 18
Dependent Claim
27 words
The material of claim 1 wherein said polyvinyl chloride particles comprise a first subset of blending grade particles and a different, second subset of dispersion grade particles.
Claim 19
Dependent Claim
27 words
The material of claim 11 wherein said polyvinyl chloride particles comprise a first subset of blending grade particles and a different, second subset of dispersion grade particles.
Claim 20
Dependent Claim
31 words
The method of claim 14 further comprising the step of providing polyvinyl chloride particles comprising a first subset of blending grade particles and a different, second subset of dispersion grade particles.
Claim 21
Dependent Claim
83 words
A foamed rigid polymeric material comprising: a. a continuous phase of polyurethane defining a multiplicity of microcells having a diameter of about 1 millimeter or less, wherein the polyurethane is the product of a reaction between methylene diisocyante and a polyol; and b. solid polyvinylchloride particles substantially uniformly dispersed in the continuous phase, wherein the particles have surface features effective to provide a multiplicity of seed bubble sites and which serve to stabilize and reinforce the microcellular structure of the foamed polymeric material.
Claim 22
Dependent Claim
83 words
A foamed rigid polymeric material comprising: a. a continuous phase of polyurethane defining a multiplicity of microcells having a diameter of about 1 millimeter or less, wherein the polyurethane is the product of a reaction between methylene diisocyante and a polyol; and b. solid polyvinylchloride particles substantially uniformly dispersed in the continuous phase, wherein the particles have surface features effective to provide a multiplicity of seed bubble sites and which serve to stabilize and reinforce the microcellular structure of the foamed polymeric material.
Claim 23
Dependent Claim
19 words
The material of claim 18 wherein the continuous phase defines cells uniformly no greater than 0.1 millimeter in diameter.
Claim 24
Dependent Claim
25 words
The material of claim 18 wherein the polyvinyl chloride particles have an average diameter within the range of about 5 microns to about 50 microns.
Claim 25
Dependent Claim
12 words
The material of claim 18 wherein the polyol comprises a polyether polyol.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1995-02-03 | 1995-08-05 | 1996-02-04 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-02-03 | 1999-08-05 | 2000-02-04 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-02-03 | 2003-08-05 | 2004-02-04 | $7700.00 | Window Closed / Lapsed |